Stay Ahead of Corrosion Costs with CMAP from The Lab

Corrosion remains one of the costliest challenges for shipowners, with the estimated collective global cost to shipowners as high as US$80 billion, according to The Association for Materials Protection and Performance (AMPP). Even testing for corrosion can be a costly endeavour, with traditional corrosion assessments often involving stripping back coatings or teak decking before any inspection can begin.

Understanding the needs of shipowners looking to keep maintenance and repair costs down, The Lab’s Non-Invasive Corrosion Mapping (CMAP) service uses pulsed Eddy-current technology to scan through non-conductive coatings and deliver a comprehensive, ship-wide view of steel condition without the need for intrusive preparation. At its core, CMAP combines an electromagnetic technique with bespoke naval-grade probes to measure wall loss in steel structures beneath paint, teak or insulation.

“If you do not want to remove paint, sandblast or strip back teak decking on a cruise ship or superyacht, our technology will scan straight through,” Arron Jackaman, Director of Non-destructive Testing at The Lab, explains. “The system then compares the measured wall thickness with as-built drawings to discover how much metal has corroded, either as a single snapshot or over time, making CMAP a highly effective monitoring tool for today’s modern ship owner and operator.”

While the pulsed Eddy-current hardware is supplied by Eddyfi, The Lab has developed its own suite of probes that are optimised for maritime applications. More importantly, the firm’s 3D corrosion-mapping software overlays data on detailed ship schematics, producing a digital twin that highlights exactly where maintenance is required. “We map all corrosion to the actual ship drawings in three dimensions,” Arron says. “This service is not just for flat plates. We have scanned hulls, tanks, tank tops and complex superstructure elements in the past, showing how versatile this technology really can be for the wider maritime sector.”

Rather than removing expensive coatings and coverings in dry dock, owners can use The Lab’s CMAP technology to decide whether to perform immediate repairs or continue monitoring the area during its next inspection interval.

“If you know the extent of corrosion before you enter dry dock you will not be caught out,” Arron points out.  Early visibility also ensures yards order the correct amount of steel, keeping all players involved in vessel maintenance as efficient as possible. “Lead times for new steel inserts can be quite long,” he explains. “Owner’s have a habit of over-ordering ‘just in case’, wasting money and materials. Corrosion mapping helps them order precisely what they need, cutting waste and carbon emissions.”

Since CMAP’s launch, The Lab has applied the technology across a huge variety of vessels. Arron highlights work on cruise liners and ferries where scanning was undertaken overnight with passengers on board. “It is truly non-invasive; the crew and passengers were unaffected,” he recalls. Superyachts, naval vessels, and offshore platforms have all also gained from CMAP’s ability to scan through insulation and coatings without causing too much disruption.

With the success of CMAP already well established, the next frontier for The Lab is in-water mapping. With accreditation from Lloyd’s Register, the team is researching marinised probes that will enable CMAP to be performed while the vessel remains afloat. Such capability would further reduce downtime and extend the service’s reach into continuously operating fleets.

CMAP not only streamlines operations but also underpins environmental stewardship. By avoiding unnecessary panel removal and repeat dry-dock visits, owners cut energy use, chemical waste and carbon emissions. “Corrosion mapping feeds perfectly into the sustainability work our clients are doing and are increasingly focused on. It allows decision makers to only order the steel they need, plan and reduce downtime well ahead of time, limit material waste and reduce their carbon footprint.”

Forward-looking owners recognise CMAP as essential for both maintenance foresight and environmental compliance. As classification societies and regulators emphasise green credentials, CMAP’s blend of non-destructive testing and digital-twin reporting positions The Lab and Brookes Bell at the forefront of sustainable vessel maintenance.